Tonneau cover

ABSTRACT

Rigid panel sections can include a rigid panel, a first frame member, a second frame member and a coupling mechanism. The rigid panel can have a first face, a second face opposite the first face, and an edge therebetween. The first face can having a first margin adjacent the edge and the second face can have a second margin adjacent the edge. The first frame member can be disposed along at least a portion of the edge and can have a first flange overlying the first margin. A second frame member, distinct from the first frame member, can be disposed along at least a portion of the edge and can have a second flange overlying the second margin. The coupling mechanism connecting the second frame member and the first frame member together can be positioned outboard of the edge. Methods of assembling the rigid panel sections are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/186,703, filed on Jun. 30, 2015. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present disclosure relates to tonneau covers for vehicles and, moreparticularly, relates to a two-piece frame member connected to an edgeof a rigid panel of a tonneau cover.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Tonneau covers have been used for a number of years to cover the truckbed or cargo box of pickup trucks, to protect against dirt, debris, andother environmental contaminants, and to improve the aesthetic qualitythereof. Such tonneau covers can be foldable when not being used tocover the bed of the pickup truck or for cargo protection or tootherwise allow access to the truck bed. Tonneau covers which includesolid panels can be desirable, for example, to provide strength andrigidity and for their aesthetic quality. The present disclosureprovides improvements in foldable tonneau covers incorporating rigidpanels and in methods of assembling such tonneau covers.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In accordance with one aspect of the present disclosure, a tonneau coverfor covering a truck bed can include a plurality of rigid panel sectionsfoldable between a deployed arrangement for covering the truck bed and afolded arrangement wherein the panel sections are stacked for accessingthe truck bed. Such a tonneau cover can include at least one rigidsection including a rigid panel, a bottom frame member, a top framemember and a coupling mechanism connecting the top frame member andbottom frame member together. The rigid panel can have a bottom faceadapted to face the truck bed when the tonneau cover is in the deployedarrangement. The rigid panel can further have a top face opposite thebottom face, and an edge therebetween. The top face can have a topmargin adjacent the edge, and the bottom face can have a bottom marginadjacent the edge. The bottom frame member can be disposed about theedge and can have a bottom flange overlying the bottom margin of therigid panel. The coupling mechanism can connect the top frame member andthe bottom frame member together via coupling elements positionedoutboard of the edge.

In accordance with another aspect of the present disclosure, a tonneaucover for covering a truck bed can include a plurality of rigid panelsections configured to cover the at least a portion of the truck bed. Atleast one of the plurality of rigid panel sections can include a rigidpanel, a first frame member, a second frame member and a couplingmechanism connecting the first frame member and the second frame membertogether. The rigid panel can have a first face, a second face oppositethe first face, and an edge therebetween. The first face of the rigidpanel can having a first margin adjacent the edge. The second face ofthe rigid panel can have a second margin adjacent the edge. The firstframe member can be disposed along at least a portion of the edge andcan have a first flange overlying the first margin. The second framemember can be distinct from the first frame member and can be disposedalong at least a portion of the edge and can have a second flangeoverlying the second margin. The coupling mechanism can connect thesecond frame member and the first frame member together outboard of theedge.

In accordance with a further aspect of the present disclosure, a methodof assembling a tonneau cover can include providing a rigid panel havinga first face, a second face opposite the first face, and an edgetherebetween, with the second face having a second margin adjacent theedge, and the first face having a first margin adjacent the edge. Afirst frame member can be disposed along at least a portion of the edgeof the rigid panel such that a first flange of the first frame member isoverlying the first margin. A second frame member, distinct from thefirst frame member, can be disposed along at least a portion of the edgeof the rigid panel such that a second flange of the second frame memberis overlying the second margin. The first frame member and the secondframe member can be coupled together via a coupling mechanism that ispositioned outboard of the edge of the rigid panel.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view illustrating a foldable tonneau cover inaccordance with the present disclosure in an unfolded configurationextending over a truck bed or cargo box of a pickup truck.

FIG. 2 is a partial cross-section view of one example embodiment of atonneau cover for a truck bed in accordance with the present disclosure.

FIG. 3 is a partial exploded view of the embodiment of FIG. 2.

FIGS. 4A, 4B and 4C are partial cross-sectional views illustrating theembodiment of FIG. 2 in various stages during an assembly process inaccordance with the present disclosure.

FIG. 5 is a partial cross-section view similar to FIG. 2 of anotherexample embodiment of a tonneau cover for a truck bed in accordance withthe present disclosure.

FIG. 6 is a partial exploded view similar to FIG. 3 of therepresentative embodiment of FIG. 5.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

At the outset, it should be noted that FIGS. 1 through 6 illustratevarious example embodiments of the present tonneau cover 10 havingalternative structures. However, in the interest of brevity, theembodiments will be described herein using common reference numerals toidentify common elements, although the corresponding elements in thevarious embodiments may not be identical. It should be understood,however, that the present description should not be regarded as limitingthe invention to any singular configuration and that alternativeconfigurations, not illustrated, are further within the scope of thepresent teachings.

With particular reference to FIG. 1, a tonneau cover 10 for covering atruck bed or cargo box 11 is provided. In some cases, the truck bed orcargo box 11 can be part of a pickup truck 13 as shown. In someembodiments, the tonneau cover 10 can include a plurality of rigid panelsections 12 foldable between a deployed arrangement covering the truckbed 11 and a folded arrangement wherein the panel sections 12 arestacked, allowing access to the truck bed 11.

Referring to FIGS. 1 through 6, the tonneau cover 10 can include atleast one rigid section 12. This rigid section 12 can include a rigidpanel 14 having a bottom face 16 adapted to or positioned to face thetruck bed 11 when the tonneau cover 10 is in the deployed arrangement.The rigid panel 14 can have a top face 18 opposite the bottom face 16,and an edge 20 between the top face 18 and the bottom face 16. The topface 18 can include a top margin 22 adjacent the edge 20. Similarly, thebottom face 16 can include a bottom margin 24 adjacent the edge 20.

In some instances, the top face 18 and bottom face 16 can be provided bytop and bottom outer sheet layers or skins, 19 and 17, respectively,which can be made of metal or plastic material, that sandwich a centralrigid foam core 21. As non-limiting example materials, skins 17, 19 canbe made of aluminum or fiberglass reinforced polymer and the core 21 towhich they can be laminated, can be made of a rigid polymeric orthermoplastic olefin.

The tonneau cover 10 can further include a bottom frame member 26disposed about the edge 20 and having a bottom flange 28 overlying thebottom margin 24. The tonneau cover 10 can also include a top framemember 30, distinct from the bottom frame member 26, disposed about theedge 20 and having a top flange 32 overlying the top margin 22. Althoughthe faces, margins, and flanges are distinguished in this descriptionusing the terms “top” and “bottom,” it is equally appropriate to usealternative distinguishing language, such as “first” and “second” framemembers, or “main” and “secondary” (or “lock strip”) frame members.

The tonneau cover 10 includes a coupling mechanism 34 connecting the topframe member 30 and the bottom frame member 26 outboard the edge 20. Thecoupling mechanism 34 can include a coupling element 40 on one of theframe members 30 and a cooperating coupling element 36 on the other ofthe frame members 26 that cooperate to couple the top frame member 30and bottom frame member 26 together. For example, the coupling elements36 and 40 can interlock or inter-engage with each other.

In some embodiments, one of the top frame member 30 and bottom framemember 26 can comprise a coupling element in the form of a hook 36, andthe other of the top frame member 30 and bottom frame member 26 cancomprise a cooperating coupling element in the form of a catch feature40, which can be disposed within a receptacle 38 to insure and retainthe interlocking arrangement or position. The coupling mechanism 34 canthus comprise hook 36 received in receptacle 38 to engage cooperatingcatch feature 40. In some embodiments, catch feature 40 can extend in adirection laterally away from edge 20 and hook 36 can include a flangeextending laterally toward edge 20 and engaging the catch feature 40.

In some embodiments, top frame member 30 and bottom frame member 26 caneither or both be formed as a unified one-piece extruded strip. Forexample, in the embodiment of FIGS. 2 through 4C, both of the top framemember 30 and bottom frame member 26 can be a unified extruded metalstrip, such as a unified extruded aluminum strip. In the exampleembodiment of FIGS. 5 and 6, the bottom frame member 26 can be a unifiedextruded metal strip, while the top frame member 30 can be a unifiedextruded strip that is more flexible, such as a thinner or more flexiblemetal material or a plastic material, which can aid in sealing betweenthe panel 14 and the top frame member 30.

In some embodiments, the coupling mechanism, such as the cooperatinghook 36 and catch 40 coupling elements, can be integrally formed as apart of such respective extruded strips. In some cases, the couplingmechanism 34 can include automatic or one-step cooperating couplingelements, such as the cooperating inter-engaging or interlocking hook 36and catch 40 elements. In other words, the coupling mechanism 34 cancouple the top frame member 30 and bottom frame member 26 togethersimply by appropriately positioning them with respect to each other,which can include positioning the hook 36 within a receptacle 38 housingthe catch 40.

In other cases, the coupling mechanism 34 can include one or moredistinct or separate components beyond the top frame member 30 and thebottom frame member 26. For example, the coupling elements of thecoupling mechanism 34 can include screws, pins, rivets, or clips, orother elements while cooperating coupling elements 40 can includethreaded or non-threaded apertures, or other separate elements orintegral features of one of the top frame member 30 or bottom framemember 26.

In some embodiments, top flange 32 and bottom flange 28 apply acompressive force against opposing sides of the rigid panel 14 when thetop frame member 30 and the bottom frame member 26 are coupled togetherby the coupling mechanism 34 to retain the rigid panel 14 therebetween.In other words, top frame member 30 and bottom frame member 26 and thecoupling mechanism 34 can be positioned, can have a structure, or both,that can exert a compressive force against rigid panel 14 when the rigidpanel 14 is retained between the top frame member 30 and bottom framemember 26 with these components assembled together in a collective,mated arrangement.

Referring to FIGS. 4A-4C, tonneau cover 10 can comprise a material 42disposed along an interface between any combination of top frame member30, bottom frame member 26, and rigid panel 14. In some embodiments, thematerial 42 can be an adhesive, a sealant, or other suitable material.The material 42 can be applied as a strip, a bead, a liquid, a solid, orany other suitable means. In particular, in some embodiments, thematerial 42 can be an adhesive and/or sealant applied in the form of abead to one or both of the top flange 32 or top margin 22 to providesealing and/or bonding between the top flange 32 and top margin 22. Insome embodiments, the material 42 can alternatively or additionally beapplied as a bead to one or both of the bottom flange 28 or bottommargin 24 to provide sealing and/or bonding between the bottom flange 28and the bottom margin 24.

In other cases, the material 42 can alternatively or additionally beapplied in the form of a weather-strip or vibration isolation strip asdescribed above with respect to the adhesive and/or sealant bead(s). Inother cases, sealing can be partially or completely provided by formingone of the top frame member 30 or bottom frame member 26 of a flexibleor resilient material. For example, top frame member 30 or panel lockstrip of FIGS. 5 and 6 can comprise a unified extruded plastic flexible,resilient member. Such a structure can provide sealing and or vibrationdampening instead of or in addition to the bead or strip material 42described above.

The description herein of the panels 14 being rigid does not exclude thesituation where the rigid panels 14 are partially or completely coveredwith fabric, textile or other flexible sheet material (not shown). Forexample, any of the panel 14, top frame member 30, bottom frame member26, can be partially or fully covered by such a sheet material. As butone example, such a sheet material can cover the top surfaces of thepanel 14 and top frame member 30 and can extend into and terminatewithin a cover retention slot 41.

According to the present teachings, a method of assembling the tonneaucover 10 is further provided. Referring to FIGS. 2 through 4C, themethod can include providing a rigid panel 14 having a first or top face18, a second or bottom face 16 opposite the first face 18, and an edge20 therebetween. The first face 18 includes a first margin 22 adjacentthe edge 20 and the second face 16 includes a second margin 24 adjacentthe edge 20.

The method includes disposing a first frame member 30 along at least aportion of the edge 20 of the rigid panel 14 such that a first flange 32of the first frame member 30 is overlying the first margin 22. Aplurality of first frame members 30 can in some embodiments bepre-assembled together to form a rectangular frame that is sized tocorrespond to the dimensions of the rigid panel 14. Such a pre-assembledrectangular frame can be formed, for example, of four first framemembers 30 having an identical cross-section. Alternatively, two firstframe members 30 can be positioned on opposite sides of the rigid panel14 and interconnected by intermediate frame members having a differentconfiguration.

Alternatively, an assembled rectangular frame comprising a plurality ofthe first frame members 30, these second frame members 26 can be formedin place, by individually or separately serially positioning first framemembers 30 adjacent a corresponding side or edge 20 of the panel 14. Inother embodiments a complete rectangular frame assembly need not beformed at all. For example, in some embodiments, a first frame member 30coupled to a second frame member 26 can be provided along only one edge20 of the rigid panel 14. As another example, a first frame member 30coupled to a second frame member 26 the first frame members 30 can beprovided along only two opposite edges 20 of the rigid panel 14 parallelto each other, without any other frame members along the other set ofparallel edges of the panel 14 to complete a rectangular frame. Ofcourse, other embodiments may include any other possible arrangements.

As illustrated in FIG. 4A, the first frame member 30 can, for example,be positioned such that first flange 32 faces generally upwardly. Theadhesive and/or sealant material 42 can be readily applied upon thegenerally upwardly facing first flange 32. The first margin 22 of therigid panel 14 can then be positioned directly over the first flange 32and lowered into place against the adhesive and/or sealant material 42,first flange 32, or both, without the need for relative lateral movementbetween the first flange 32 and the first margin 22 or rigid panel 14.Avoiding such relative lateral movement can facilitate better adhesionor sealing by the material 42 between the components.

As illustrated in FIG. 4B, the material 42 can be applied to the secondmargin 24 of the rigid panel 14, with the second margin 24 positionedfacing generally upwardly. As illustrated in FIG. 4C, the method canfurther include disposing a second frame member 26 or locking strip,distinct from the first frame member 30, along at least a portion of theedge 20 of the rigid panel 14 such that the second flange 28 of thesecond frame member 26 overlays the second margin 24. The second flange28 of the second frame member 26 can be positioned directly over thebottom or second margin 24 of the rigid panel 14 and lowered into placeagainst the intervening material 42, bottom or second flange 28, orboth, without the need for relative lateral movement between the secondflange 28 or the material 42, and the second margin 24 of the rigidpanel 14, which also can facilitate better adhesion or sealing by thematerial 42 between the components.

As described above, regarding the first frame members 30, these secondframe members 26 can be pre-assembled into a rectangular frame assembly,or can be individually or separately serially positioned above andcoupled to a corresponding first frame member 30 along the sides of thepanel 14. As the first flange 32 and second flange 28 of the first framemember 30 and the second frame member 26 is being positioned against thecorresponding first and second margins, 22 and 24, respectively, thecoupling elements 36 and 40 of the coupling mechanism 34 caninter-engage or interlock to couple the first frame member 30 and thesecond frame member 26 together. In some embodiments, the method caninclude coupling the first frame member 30 and the second frame member26 together outboard the edge 20 of the rigid panel 14. In other words,the coupling elements 36 and 40 can be positioned outboard of the edges20 of the rigid panel 14.

In some embodiments, first and second frame members 30 and 26,respectively, can be coupled together around opposing sides of the panel14. A first coupling extension of corner frame members 31 can next beinserted into ends of these opposing coupled frame members 30, 26. Then,first and second frame members 30 and 26, respectively, can bepositioned and coupled together along the remaining two sides of thepanel 14 and around second coupling extensions of each corner framemember 31.

In some embodiments, the adhesive and/or sealant material 42 can beapplied between the first flange 32 of the first frame member 30 and thefirst margin 22 prior to the step of disposing the first frame member 30along at least the portion of the edge 20 of the rigid panel 14. In someembodiments, the method can include applying an adhesive and/or sealant42 between the second flange 28 of the second frame member 26 and thesecond margin 24 prior to the step of disposing the second frame member26 along at least the portion of the edge 20 of the rigid panel 14. Inother embodiments, such adhesive and/or bonding material, may beprovided at only one of these interfaces, or at neither interface.

The method as described above with regard to the embodiment of FIGS. 2through 4C identifies the first frame member as the top frame member 30and the second frame member as the bottom frame member 26. This need notbe the case. For example, with regard to the embodiment of FIGS. 5 and6, the first frame member in the method description above can be bottomframe member 26 and the second frame member can be top frame member 30.Likewise, the method described above with regard to the embodiment ofFIGS. 2 through 4C identifies the first flange and first margin as thetop flange 32 and top margin 22, respectively, and the second flange andsecond margin as the bottom flange 28 and bottom margin 24,respectively. With regard to the embodiment of FIGS. 5 and 6, the firstflange and first margin can be the bottom flange 28 and bottom margin24, respectively, and the second flange and second margin can be the topflange 32 and top margin 22, respectively.

Example embodiments are provided so that those who are skilled in theart can fully understand the tonneau covers for truck beds in accordancewith this disclosure. These example embodiments provide numerousspecific details such as examples of specific components, shapes,devices, and methods, to provide a thorough understanding of embodimentsof the present disclosure. It will be apparent to those skilled in theart that specific details need not be employed, that example embodimentsmay be embodied in many different forms and that neither should beconstrued to limit the scope of the disclosure. Similarly, any aspect orcombination of aspects illustrated or described in reference to oneembodiment may be used in combination with one or more aspectsillustrated or described in reference to any other embodiments. In someexample embodiments, well-known processes, well-known device structures,and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A tonneau cover for covering a cargo bed, thetonneau cover comprising a plurality of rigid panel sections foldablebetween a deployed arrangement for covering the cargo bed and a foldedarrangement wherein the panel sections are stacked for accessing thecargo bed, the tonneau cover including at least one rigid sectioncomprising: a rigid panel having a bottom face adapted to face the cargobed when the tonneau cover is in the deployed arrangement, a top faceopposite the bottom face, and an edge therebetween, the top face havinga top margin adjacent the edge, the bottom face having a bottom marginadjacent the edge; a bottom frame member disposed about the edge andhaving a bottom flange overlying the bottom margin; a top frame memberdistinct from the bottom frame member, the top frame member beingdisposed about the edge and having a top flange overlying the topmargin; and a coupling mechanism connecting the top frame member and thebottom frame member outboard the edge; wherein at least one of the toframe member and the bottom frame member comprises a hook, and whereinthe other of the top frame member and the bottom frame member comprisesa receptacle and a catch feature disposed within the receptacle, andwherein the coupling mechanism comprises the hook received in thereceptacle and engaging the catch feature.
 2. The tonneau coveraccording to claim 1 wherein the catch feature extends in a directionaway from the edge, and wherein the hook comprises a flange extendingtoward the edge and engaging the catch feature.
 3. The tonneau coveraccording to claim 1 wherein the top frame member is formed of anextruded strip, and wherein the bottom frame member is formed of anextruded strip.
 4. The tonneau cover according to claim 1 wherein thetop flange and the bottom flange apply a compressive force to retain therigid panel.
 5. The tonneau cover according to claim 1, furthercomprising an adhesive bead bonding the top flange and the top margin.6. The tonneau cover according to claim 1, further comprising anadhesive bead bonding the bottom flange and the bottom margin.
 7. Thetonneau cover according to claim 1, further comprising a sealant beadforming a seal between the top flange and the top margin.
 8. The tonneaucover according to claim 1, further comprising a sealant bead forming aseal between the bottom flange and the bottom margin.